Furniture devices and methods

ABSTRACT

Furniture frames, such as futon frames, are movable between bed configurations and sofa configurations. Furniture frame embodiments according to the invention provide a more level, continuous and secure sleep surface than currently available. The central gap present in many futon frames, for example, is eliminated, as is a fourth cross rail. Manufacturing costs are reduced, and reliability is improved. Additionally, furniture frame embodiments include at least one topple member that engages the top of a depending backrest side or side and does not put pressure on a hole accommodating a pivot pin connecting the backrest panel and seat panel. Mechanical advantage is improved. Further, a working end of the depending backrest side can be produced with a single cut, eliminating the need for multiple cuts and/or attachment of separate pieces, thereby lowering manufacturing costs. Corresponding methods provide similar advantages.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The subject matter of this application is related to the subjectmatter of U.S. Patent Application No. 60/134,720, filed May 18, 1999,and 60/147,305, filed Aug. 5, 1999, priority to both of which is claimedunder 35 U.S.C. § 119(e) and both of which are incorporated herein byreference.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The invention relates to furniture, and more particularly tofurniture frames, such as futon frames, that are movable between sofaand bed configurations.

[0004] 2. Description of Related Art

[0005] The futon industry is enjoying tremendous growth across theUnited States and elsewhere. Futons, futon frames, and similarconvertible furniture products are offered in a wealth of styles andoptions, offering multi-use functionality and practicality at areasonable price. As with any growing industry, a producer that canimprove the reliability, durability, and attractiveness of its products,make its products more comfortable and easier to use, and reduce its ownmanufacturing costs and complexity, stands to reap a substantial reward.The futon industry is no exception. Embodiments of the invention providethese advantages and offer significant improvements over the prior art.

[0006] FIGS. 1-3 show conventional futon frame 10. Substantiallyrectangular pivoting member 15, which can also be bell-shaped, ispivotally coupled to and hangs down from seat panel 20. Pivoting member15 engages kicker attachment 25 to backrest panel 30. Kicker attachment25 defines substantially L-shaped notch 35. As shown in FIG. 2, pivotingmember 15 engages kicker attachment 25 at L-shaped notch 35 to liftbackrest 30 to the sofa configuration of FIG. 1. Ultimately, futon frame10 can be returned to a bed configuration like that shown in FIG. 3.

[0007] Embodiments of the present invention offer improvements overfuton frames like those shown in FIGS. 1-3. Creating L-shaped notch 35in kicker attachment 25 is quite labor-intensive, and thus expensive.Moreover, kicker attachment 25 is quite prone to breakage, e.g. alongthe grain and/or along a line extending through pivot pin 40, whichconnects backrest 30 and seat panel 20. Substantial stress is alsoexerted on pivoting member 15, especially at the point of its pivotalconnection to seat panel 20. It can also be difficult to tell whenpivoting member 15 has moved to a position of proper engagement withkicker attachment 25.

[0008] Aside from these mechanical issues, futon frame 10 also presentsa disadvantage in that a substantial gap 45 is created between seatpanel 20 and backrest panel 30 when futon frame 10 is in the bedconfiguration of FIG. 3. Gap 45 typically is 2-3 inches wide and cancreate unevenness in a futon or pad placed over frame 10. An unevensleep surface causes general discomfort, especially for a single user ofthe futon in the bed configuration. Another problem arises in that gap45 is bordered by two cross rails 50, which run entirely across thelength of frame 10. Unless precisely aligned, each cross rail 50 cancreate a ridge or other uneven surface with respect to slats 55. Thisridge-gap-ridge profile down the center of frame 10 adds to thediscomfort potentially experienced by a user of frame 10.

[0009] Finally, frame 10 includes not only cross rails 50 but also twoadditional cross rails 60, for a total of four cross rails. These longboards are relatively expensive, increasing manufacturing costs.Further, the cross rail 50 at the back of seat panel 20 tends to break,e.g. when a user sits down hard or jumps on frame 10 in its sofaconfiguration. Therefore, a number of such futon frames include one ormore additional short support boards to reinforce the long boards, whichagain increase labor and material costs.

[0010] A number of prior art futon designs are illustrated and describedin e.g. U.S. Pat. Nos. 3,634,893, 4,538,308, 4,642,823, 4,829,611,4,875,244, 4,996,730, 5,146,640, 5,153,952, 5,303,432, 5,315,722,5,327,591, 5,509,151, 5,513,398, 5,519,902, 5,628,076, 5,664,268,5,722,101, 5,790,993, 5,815,858, all of which are incorporated byreference herein.

SUMMARY OF THE INVENTION

[0011] Embodiments of the invention overcome the above and/or otherdisadvantages. Embodiments of the invention reduce labor, material andother furniture manufacturing costs, improve comfort for the user offurniture items, increase reliability and longevity of furniture items,and provide other advantages.

[0012] More specifically, for example, a topple member according to anembodiment of the invention engages the top of a depending backrest sideand does not put pressure on a hole accommodating a pivot pin connectingthe backrest panel and seat panel. Further, a working end of thedepending backrest side can be produced with a single cut, eliminatingthe need for multiple cuts and/or attachment of separate pieces, therebylowering manufacturing costs. The depending backrest side according toembodiments of the invention increases the lever arm between the pivotpin and the point of engagement with the topple member, providinggreater torque and decreasing the amount of pushing force the operatoris required to exert.

[0013] Additionally, embodiments of the invention provide a more level,continuous and secure sleep surface than available with many currentfuton frames. The central gap present in many futon frames, for example,is eliminated. Manufacturing costs are reduced, and reliability isimproved.

[0014] Certain embodiments described and illustrated herein are“wall-hugging” embodiments, that is, the backrest panel can be placedsubstantially against a wall when the furniture frame is in the sofaconfiguration, and remain against the wall even when the furniture frameis shifted to a bed configuration. Further, a user can change the framefrom the bed configuration to the sofa configuration and vice versasolely from the front of the frame.

[0015] Other advantages and features according to the invention will beapparent to those of ordinary skill upon reading this application.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Embodiments of the invention will be described with respect tothe figures, in which like reference numbers denote like elements and inwhich:

[0017]FIG. 1 is a perspective view of a typical futon frame in a sofaconfiguration;

[0018]FIG. 2 is an alternative perspective view of the FIG. 1 frame in atransitional configuration;

[0019]FIG. 3 is an alternative perspective view of the FIG. 1 frame in abed configuration;

[0020]FIG. 4 is a perspective view of a futon frame according to anembodiment of the invention;

[0021] FIGS. 5-14 are perspective views of the FIG. 4 futon frame inalternative configurations;

[0022]FIG. 14A is a side view of a topple member according to anembodiment of the invention;

[0023]FIG. 15 is a side view of a topple member according to anembodiment of the invention;

[0024]FIG. 16 is a side view of a topple member according to anembodiment of the invention;

[0025]FIG. 17 is a side view of a topple member according to anembodiment of the invention;

[0026]FIG. 18 is a side view of a topple member according to anembodiment of the invention;

[0027]FIG. 19 is a perspective view of a futon frame according to anembodiment of the invention;

[0028]FIG. 20 is a perspective view of a futon frame according to anembodiment of the invention;

[0029]FIG. 21 is a perspective view of a futon frame according to anembodiment of the invention;

[0030]FIG. 22 is a side schematic view of a futon frame according to anembodiment of the invention;

[0031]FIG. 23 is a side schematic view of the FIG. 22 frame in analternative configuration;

[0032]FIG. 24 is a side view of an alternative slat fasteningarrangement according to an embodiment of the invention; and

[0033]FIG. 25 is a perspective view of the FIG. 20 frame in a foldedconfiguration.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0034] Embodiments of the invention and associated operational stepsfirst will be described together with respect to FIGS. 4-14. Morespecifically, a topple member feature for a futon or similar piece offurniture will first be described. Topple members according toembodiments of the invention allow a user to easily operate a futonframe or other furniture frame from the front, e.g. to move the framebetween a bed configuration and a sofa configuration. The topple membersare sturdy and reliable, providing leveraged mechanical advantage in amanner believed heretofore unknown in the prior art.

[0035] As shown in e.g. FIG. 4, user 100 picks up a forward portion 105of futon frame 110, also called a seat panel, when frame 110 is in a bedconfiguration. In the bed configuration, seat panel 105 and back portion115, also called a backrest panel, together are in a generallyhorizontal plane. Forward leg 120 of frame 110 engages the floor orother underlying support, and seat panel 105 and backrest panel 115together present a generally flat surface for supporting a futon,mattress, cushion or the like.

[0036] Further structural details according to embodiments of theinvention are visible in e.g. FIGS. 4-7. Futon frame 110 includes arms125, as shown. Seat panel 105 includes a plurality of slats 130extending in a transverse direction of frame 110, and backrest panel 115includes a plurality of slats 135 also extending in a transversedirection. Frame 110 also includes longitudinal cross member 140, alsocalled a bottom back rail, which contacts and supports both thetransverse slats 130 of seat panel 105 and the transverse slats 135 ofbackrest panel 115. As will be described later, e.g. with respect toFIGS. 22-23, frame 110 also includes two additional longitudinal crossmembers: front seat rail 145 and top back rail 148.

[0037] Seat panel 105 is lifted from the position of FIG. 4 to andthrough the positions of FIGS. 5-6, as shown, to begin the process ofmoving furniture frame 100 from the bed configuration to a sofaconfiguration. In the sofa configuration, as will be recognized by thoseof ordinary skill, seat panel 105 and backrest panel 115 are disposed atan angle to each other.

[0038] Topple member 150 for the illustrated futon frame 110 is visiblein e.g. FIGS. 5-6, substantially in the shape of a trapezoid accordingto this particular embodiment. Topple member 150 defines a relativelyshorter first end or “nose” portion 155, shown in FIG. 5 as therightmost portion of topple member 150. Topple member 150 also defines arelatively longer second end or “tail” portion 160, shown in FIG. 5 asthe leftmost portion. Although a single topple member is alsocontemplated according to the invention, the embodiment of the figuresincludes two substantially identical topple members 150: one at the nearend of futon frame 110 as viewed in e.g. FIG. 4, and one at the far end.To simplify the disclosure, only one of the two topple members 150generally will be referenced herein.

[0039] Topple member 150 is pivotally connected to seat panel 105 atpivot pin 165 disposed between first end 155 and second end 160. As willbe apparent from FIG. 5, the center of gravity of topple member 150 isdisposed above pivot pin 165, for reasons to be explained.

[0040] Pivot pin 165 extends through a corresponding hole in topplemember 150 and is anchored into seat side 170 at a side of seat panel105, as shown. The center of gravity of topple member 150 is constructedto be above and to the left of pivot pin 165 in e.g. the configurationof FIGS. 5-6. Further, pivot pin 165 is disposed substantially below aline extending from the lower left corner to the upper right corner oftopple member 150 as viewed in FIG. 5.

[0041] In FIGS. 5-6, first end or nose 155 of topple member 150 engagesengagement slat 175 of seat panel 105. Engagement slat 175 extendsgenerally parallel to remaining slats 130 of seat panel 105 and to slats135 of backrest panel 115 when futon frame 110 is in the bedconfiguration, according to this embodiment. Engagement slat 175 can besubstantially shorter than the other slats, e.g. extending just farenough to engage nose 155 and tail 160 of topple member 150, or can begenerally the same length as the other slats. According to still furtherembodiments, engagement slat 175 can be eliminated altogether, as willbe described.

[0042] As user 100 continues to lift seat panel 105 from e.g. the FIG. 6position, the center of gravity of topple member 150 shifts from theleft of pivot 165 to the right of pivot 165, as viewed in the figure.This shift in the center of gravity rotates or topples topple member 150over, until tail portion 160 thereof hits engagement slat 175, as shownin FIG. 7. At this point seat panel 105 is ready to be lowered, toengage backrest side 180 and elevate backrest panel 115, as will bedescribed.

[0043] When tail 160 of topple member 150 hits engagement slat 175, anaudible “clicking” or other sound is made. When two topple members 150on opposite sides of frame 110 are provided and hit their respectiveengagement slats, an aesthetically pleasing “click-click” sound can beheard, reassuring the user that proper engagement has occurred. Theexact character of the sound will depend on the materials from whiche.g. each topple member 150 and engagement slat 175 are constructed.Wooden materials will result in a softer and more natural sound thane.g. metal, plastic, or other materials, but such other materials arefully contemplated by the invention. According to an additionalembodiment, topple member 150 can be in the form of a bell, or otherwisehave a clapper or ringing device to present an additional or differentsound audible to the user.

[0044] According to other embodiments of the invention, a contact padcan be provided at tail 160 of topple member 150 and/or at acorresponding location on engagement slat 175. The contact pad can beconstructed of a material to provide a desired sound characteristic whentopple member 150 comes into contact with the engagement slat 175, andcan be shaped to cover e.g. all or a portion of the edge of topplemember 150 facing engagement slat 175. Dual contact pads of differentmaterials can be provided on opposite topple members 150, to providedifferent sound qualities—e.g. a “click-clack” or “clack-click” sound,depending on which topple member 150 engages its correspondingengagement slat 175 first. Alternatively, one topple member 150 can havea contact pad and the other not. Of course, topple member 150 and/orengagement slat 175 also can be provided with cloth, padding or othermaterial to soften or mute the sound of engagement, if desired.

[0045] Although substantially simultaneous engagement of topple members150 with their respective engagement slats 175 will result insubstantially a single sound, normally there will be a slight separationin the sounds. If desired, the structural (e.g. center-of-gravity)characteristics of e.g. one or both topple members 150 can be altered,to promote non-simultaneous engagement, as will be described below withrespect to FIGS. 15-18.

[0046] The sound made by one or more topple members 150 alerts user 100that nose 155 of topple member 150 is in position to engage back side orbackrest side 180 depending from the side of backrest panel 115, asshown in e.g. FIG. 7. As user 100 then lowers seat panel 105 toward thefloor, nose 155 engages and pushes down on depending backrest side 180,as shown in e.g. FIGS. 8-9. As with previously described engagementslats 175, two depending backrest sides 180 can be provided, one on eachside of futon or other furniture frame 110, i.e. one for each topplemember 150.

[0047] In FIG. 7, as previously described, topple member 150 hastoppled. In other words, the center of gravity of topple member 150 hasshifted from the left of pivot pin 165, as viewed in the figure, to theright thereof. In FIG. 8, user 100 has lowered seat panel 105 until nose155 of topple member 150 has engaged depending backrest side 180. Inthis position, as shown, depending backrest side 180 supports seat panel105 in a raised position without operator support, via topple member 150and engagement slat 175.

[0048] In FIG. 9, user 100 exerts downward pressure on seat panel 105,providing mechanical advantage to lever backrest panel 115 into a moreupright position, via engagement slat 175, topple member 150 anddepending backrest side 180. Ultimately, as shown in e.g. FIGS. 10-13,futon frame 110 achieves a sofa configuration, with forward leg 120again engaging the floor to support seat panel 105.

[0049] Depending backrest side 180 is specifically constructed forstrength and durability, As shown in e.g. FIGS. 7-8, depending backrestside 180 is preferably of one-piece construction and is tapered suchthat nose 155 of topple member 150 engages a top portion thereof. Incontrast, as referenced above, the prior art mechanism of e.g. FIG. 1includes substantially rectangular pivoting member 15 that hangs downfrom seat panel 20 for engagement with kicker attachment 25. Kickerattachment 25 includes a substantially L-shaped cutout 35 for engagementwith pivoting member 15, whereas depending backrest side 180 accordingto the invention is free of this cutout portion. Notched kickerattachment 25 is quite labor-intensive (and thus expensive) to make, andis quite prone to breakage e.g. along the grain and/or e.g. along a lineextending through the pivot pin connecting the backrest and seat panel.

[0050] Frame 110 and topple member 150 according to embodiments of theinvention overcome these problems of the prior art. Topple member 150engages the top of depending backrest side 180 and does not putsignificant pressure on the hole accommodating pivot pin 165, or on thepivotal connection 185 between seat panel 105 and backrest panel 115. Inother words, at least pivot pin 165 is generally non-load-bearing.Further, the working end of depending backrest side 180 can be producedwith a single cut, eliminating the need for multiple cuts and/orattachment of separate pieces and the associated manufacturing costs.Depending backrest side 180 according to the invention increases thelever arm between pivotal connection 185 and the point of engagementwith topple member 150, providing greater torque and decreasing theamount of pushing force the operator is required to exert.

[0051] In FIG. 11, seat panel 105 is now pushed in, toward backrestpanel 115, to release topple member 150. As shown in FIG. 12, topplemember 150 then becomes disengaged, toppling back out of the way. Seatpanel 105 then can be pulled out, if desired, as shown in e.g. FIG. 13,causing futon frame 110 to enter a “lounge” or partially reclinedconfiguration. Topple member 150 causes frame 110 to stop in the loungeposition, when hanging tail 160 of topple member 150 engages front rail190 extending between and connecting the two arm panels 125 of futonframe 110. Front rail 190 is shown in e.g. FIGS. 6 and 12, and FIG. 12additionally shows tail 160 of topple member 150 poised to engage frontrail 190 once seat panel 105 is pulled out in the manner of FIG. 13.

[0052] As shown in e.g. FIG. 14, embodiments of the invention alsoinclude footrest 195, which can be pulled out if desired. FIG. 14 alsoshows the newly configured futon frame 110 in a ready-to-use, sofaconfiguration. To move futon frame 110 back to the bed configuration,user 100 lifts seat panel 105 until topple member 150 clears front rail190, and then pulls seat panel 105 out until it and backrest panel 115move into a generally horizontal position.

[0053] Although topple member 150 illustrated in e.g. FIGS. 5-6 isgenerally in the shape of a trapezoid, other shapes are fullycontemplated according to the invention. For example, topple member 150can be generally in the shape of a parallelogram, triangle, or othergeometric figure. FIG. 14A, for example, shows topple member 192 havingtwo straight sides 194, 196, and curved side 198. In other words, topplemember 192 defines an outline shape consisting of two straight edges andone curved edge. As shown in e.g. FIG. 15, alternative topple member 200can comprise more than one geometric shape. In the illustrated example,topple member 200 includes triangular portion 205 rigidly affixed to orformed as one-piece with a relatively narrow elongated portion 210 thathere is generally rectangular but can be of any desired shape. Oppositeends 215, 220 of the elongated portion 210 are functionally equivalentto nose 155 and tail 160 of topple member 150 illustrated and describedpreviously.

[0054]FIG. 15 also illustrates a mechanism for shifting the center ofgravity of topple member 200, according to an embodiment of theinvention. Weight 225 is mounted to move along support rod 230, asshown. Movement of weight 225 along rod 230 can be accomplished in anumber of ways. For example, weight 225 can be generally hollow andmounted with a friction fit on rod 230, or weight 225 and rod 230 can bethreaded together such that rotation of weight 225 propels it along rod230, or weight 225 can be cantilevered off rod 230. Other ways to shiftthe center of gravity of topple member 200 also can be provided and willbe apparent to those of ordinary skill upon reading this description.

[0055] The FIG. 15 embodiment is contemplated primarily for use withmetal topple members 200 and/or associated structure, but, of course,can be used with other materials as well. By providing structure thatallows the center of gravity to be adjusted, each topple member 200present in a single futon frame or other frame 110 can be “fine-tuned”to topple at just the right time to produce a desired auditory or othereffect.

[0056] The center of gravity of a topple member according to theinvention also can be altered by drilling or otherwise providing a holethrough the topple member, reducing the weight of a certain areathereof. On the other hand, a lead or other weight can be inserted intothe hole, increasing the weight of that area. Additionally, the overallshape of the topple member can be altered to provide desiredcenter-of-gravity characteristics. For example, in addition to thegenerally triangular embodiments shown in FIG. 15, a generallytriangular topple member can be created by forming a generally straightedge between the nose and the tail of topple member 150 shown in e.g.FIG. 5. A wide variety of shapes and other structure for modifying thecenter of gravity of the topple member are contemplated.

[0057] FIGS. 16-18 illustrate several additional structural aspects oftopple members according to embodiments of the invention. Instead of orin addition to limiting topple-member pivot by the previously describedengagement slat(s) 175 and/or depending backrest side(s) 180, the FIG.16 embodiment provides slotted topple member 235. Slot 240 of member 235accommodates pin 245, which is secured to e.g. seat side 170 along withtopple member pivot pin 165. In the FIG. 17 embodiment, pivoting motionof topple member 250 is limited by engagement pins 255, 260. Pins 255,260 protrude from e.g. seat side 170 for engaging sides of triangularportion 205 of topple member 250. In the FIG. 18 embodiment, topplemember 265 includes depending L-shaped or other-shaped member 270, e.g.generally rigidly affixed with respect to the remainder of topple member265, for hooking under or otherwise engaging e.g. seat side 170 andthereby limiting pivoting motion of topple member 265.

[0058] Additional embodiments of the invention provide an interlockingslat system for a sofa, futon or similar item of furniture. The systemis engineered to eliminate at least one of the long slat supports (i.e.cross rails) present in many known furniture items, thereby reducingmanufacturing costs, while at the same time increasing overall strength.Other advantages include providing a more comfortable sleeping or lyingsurface by eliminating the usual 2-3 inch gap running down the middle ofmany previous futon frames. A footrest also can be provided. Theseembodiments of the invention will now be described in more detail.

[0059] More specifically, turning now to FIGS. 19-23, an alternativefuton frame 110 includes longitudinal cross member 140, as describedearlier. Note e.g. FIG. 20. Longitudinal cross member 140 is a part ofback panel 115,, according to the illustrated embodiment, and contactsand supports both the transverse slats 130 of seat panel 105 and thetransverse slats 135 of backrest panel 115. The arrangement of seatpanel slats 130, backrest panel slats 135, longitudinal cross member 140and the other illustrated structures allow slats 130, 135 to generallymesh with each other down the center of futon frame 110 in the bedconfiguration. This meshing or overlap is illustrated at e.g. 275 inFIGS. 19-20, and creates a generally continuous futon support surfacedown the center of frame 110, without a gap or ridge-gap-ridge profilepresent in prior art furniture items as described above. Only seat panelslats 130 and back panel slats 135 provide an underlying contact surfacefor the futon or cushion to be supported by frame 110.

[0060] As mentioned, embodiments of the invention use only three crossrails (bottom back rail 140, front seat rail 145, and top back rail 148)instead of four. Seat panel 105 includes only one (front seat rail 145),and backrest panel 115 includes only two (bottom back rail 140 and topback rail 148). The fourth cross rail present in many prior art framesis eliminated, providing the manufacturing and other advantagesdescribed previously.

[0061] Backrest panel slats 135 are each rigidly attached to both bottomback rail 140 and top back rail 148, e.g. by nails, screws, bolts orother fasteners 280 (FIG. 20), providing a rigid and squared panel. Seatpanel slats 130, on the other hand, are rigidly attached by fasteners280 only to front seat rail 145. In a manner believed unknown in theprior art, seat panel slats 130 “float” or roll/slide with respect tobottom back rail 140 and are not rigidly fastened thereto. As frame 110is moved from the bed configuration shown in e.g. FIG. 20 to the sofaconfiguration shown in e.g. FIG. 21, seat panel slats 130 float/roll onbottom back rail 140.

[0062] Embodiments of the invention thus not only provide rigidtriangulation strength, but also tie top backrest panel cross rail 148to bottom backrest panel cross rail 140 via backrest panel slats 135, togive extra support when futon frame 110 is used as a sofa. Bendingrigidity is increased, decreasing the likelihood of breakage under thestress of sitting pressure 285 (FIG. 23).

[0063] Instead of fastening back panel slats 135 to cross rails 140, 148with fasteners 280, as shown in FIG. 20, FIG. 24 is a side view showingan alternative construction. According to this embodiment, each backrestpanel slat 135 is positioned relative to seat panel slats 130 withbackrest panel cross rail support 290, nailer 295, and nails 298, asshown. The FIG. 24 embodiment provides a flush top to backrest panel115, instead of the “picket-fence” top shown in e.g. FIG. 21.

[0064] Finally, as shown in FIG. 25, seat panel 105 and backrest panel115 of an alternative futon frame can be shipped in a partiallypre-assembled condition, connected by at least one pivot 302. Asindicated by arrows 304, seat panel 105 and backrest panel 115 can befolded into a “doubled-over” configuration, with seat panel 105 andbackrest panel 115 fitting or nesting into each other face-to-face. Thealternate spacing of seat panel slats 130 and backrest panel slats 135is especially advantageous in this regard, promoting a compact,easy-to-ship package. This design presents a number of advantages,including reduced shipping volume and cost, and improved structuralsoundness and integrity during the shipping process.

[0065] Thus, embodiments of the invention provide significant advantagesover the prior art. Furniture frames according to embodiments of theinvention are stronger, easier to make and use, more durable, and lesscostly than previously known. Other advantages will be apparent to thoseof ordinary skill.

[0066] Although the invention has been described herein with respect toparticular embodiments, the invention is not intended to be limited tothose specific embodiments. For example, although this specificationspecifically references futons, embodiments of the invention are equallyapplicable to sofas, beds, sofa-beds, chairs and other items offurniture intended for use in an upright configuration and/or a moreprone or reclined configuration, and/or that are convertible between twoconfigurations. Although the above description frequently has used theterm “topple member,” other terms can readily be used to describe thesame item—e.g. pivot member, lever member, engagement member, lockingelement, to name a few. The topple member embodiments disclosed hereincan be used with the interlocking slat embodiments, but any of theembodiments disclosed herein also can be used by themselves. Finally,the trademark BLUEBIRD is currently associated with the described topplemember and associated products.

What is claimed is:
 1. A furniture frame movable between a sofaconfiguration and a bed configuration, the furniture frame comprising: aseat portion, the seat portion comprising a plurality of transverseslats; and a back portion operably connected with the seat portion byconnection structure, the back portion comprising a plurality oftransverse slats; wherein the seat portion and the back portion aremovable relative to each other to form the bed configuration of thefurniture frame, in which the seat portion and the back portion are insubstantially the same generally horizontal plane, and to form the sofaconfiguration of the furniture frame, in which the seat portion and theback portion are disposed at an angle to each other; further whereineither the seat portion or the back portion comprises a longitudinalcross member, the longitudinal cross member contacting and supportingboth the transverse slats of the seat portion and the transverse slatsof the back portion at least when the furniture frame is in the bedconfiguration.
 2. The furniture frame of claim 1, wherein the transverseslats of the back portion and the transverse slats of the seat portiongenerally mesh with each other at least when the furniture frame is inthe bed configuration.
 3. The furniture frame of claim 2, wherein thetransverse slats of the back portion and the transverse slats of theseat portion generally mesh with each other generally down thelongitudinal center of the furniture frame in the bed configuration. 4.The furniture frame of claim 1, wherein the longitudinal cross member isa slat-supporting cross rail extending longitudinally generally from oneend of the furniture frame generally to another end of the furnitureframe.
 5. The furniture frame of claim 4, wherein the furniture framecomprises only two additional longitudinal slat-supporting cross membersextending generally from one end of the furniture frame generally tosaid other end of the furniture frame, for a total of only three suchcross members.
 6. The furniture frame of claim 1, wherein the either thetransverse slats of the seat portion or the transverse slats of the backportion roll on the longitudinal cross member as the furniture framemoves between the bed configuration and the sofa configuration.
 7. Afurniture frame movable between a sofa configuration and a bedconfiguration, the furniture frame comprising: a seat panel; and a backpanel operably connected with the seat panel by connection structure;wherein the seat panel and the back panel are movable relative to eachother to form the bed configuration of the furniture frame, in which theseat panel and the back panel are in substantially the same generallyhorizontal plane to support a generally horizontal cushion, and to formthe sofa configuration of the furniture frame, in which the seat paneland the back panel are disposed at an angle to each other; furtherwherein a portion of the seat panel and a portion of the back paneloverlap with each other to form a generally continuous cushion supportsurface down a center of the furniture frame when the furniture frame isin the bed configuration.
 8. The furniture frame of claim 7, wherein theseat panel comprises a plurality of seat panel slats and the back panelcomprises a plurality of back panel slats, the back panel slats and theseat panel slats all being generally parallel to each other, only theback panel slats and the seat panel slats being constructed to providean underlying contact surface for a cushion when the furniture frame isin the bed configuration.
 9. The furniture frame of claim 7, wherein oneof the seat panel and back panel comprises a longitudinal cross rail,further wherein the other of the seat panel and back panel isconstructed to roll with respect to the longitudinal cross rail as thefurniture frame moves between the bed configuration and the sofaconfiguration.
 10. The furniture frame of claim 7, wherein one of theseat panel and back panel comprises a longitudinal cross rail, furtherwherein the seat panel comprises seat panel slats and the back panelcomprises back panel slats, further wherein either the seat panel slatsor the back panel slats are constructed to roll on the longitudinalcross rail as the furniture frame moves between the bed configurationand the sofa configuration.
 11. The furniture frame of claim 10, whereinthe connection structure comprises a pivotable member connected to theseat panel at a pivot point, the pivotable member being constructed toraise the back panel as the furniture frame moves from the bedconfiguration to the sofa configuration.
 12. The furniture frame ofclaim 11, wherein the back panel comprises an engagement member, thepivotable member being constructed to contact the engagement member at aportion of the engagement member free of a cutout.
 13. The furnitureframe of claim 11, wherein the pivotable member comprises a first endand a second end, the first end of the pivotable member beingconstructed to engage and lift the back panel when the furniture frameis being moved from the bed configuration to the sofa configuration, andthe second end of the pivotable member being constructed to engage theseat panel, separately from the pivot, such that a downward forceexerted on the seat panel exerts a lifting force on the back panel tomove the furniture frame to the sofa configuration.
 14. A furnitureframe movable between a sofa configuration and a bed configuration, thefurniture frame comprising: a seat portion; and a back portion operablyconnected with the seat portion by connection structure; wherein theseat portion and the back portion are movable relative to each other toform the bed configuration of the furniture frame, in which the seatportion and the back portion are in substantially the same generallyhorizontal plane, and to form the sofa configuration of the furnitureframe, in which the seat portion and the back portion are disposed at anangle to each other; further wherein the connection structure comprisesa topple member, the topple member comprising a first end and a secondend, the topple member being pivotally connected to the seat portion ata pivotal connection between the first end and the second end; furtherwherein the first end of the topple member is constructed to engage andlift the back portion when the furniture frame is being moved from thebed configuration to the sofa configuration, and the second end of thetopple member is constructed to engage the seat portion, separately fromthe pivotal connection between the topple member and the seat portion,such that a downward force exerted on the seat portion exerts a liftingforce on the back portion to move the furniture frame to the sofaconfiguration.
 15. The furniture frame of claim 14, constructed suchthat lifting the seat portion when the furniture frame is in the bedconfiguration causes the second end of the topple member to come intoengagement with the seat portion, separately from the pivotalconnection, and thereby create a sound audible to a user of thefurniture frame.
 16. The furniture frame of claim 15, wherein the topplemember is a first topple member, the furniture frame further comprisinga second topple member on an opposite side of the furniture frame fromthe first topple member, the furniture frame being constructed such thatlifting the seat portion when the furniture frame is in the bedconfiguration causes the first and second topple members to come intoengagement with the seat portion and thereby create two sounds audibleto a user of the furniture frame.
 17. The furniture frame of claim 14,wherein the second end of the topple member is constructed to engage aslat of the seat portion.
 18. The furniture frame of claim 14, whereinthe topple member defines an outline shape consisting of two straightedges and one curved edge.
 19. The furniture frame of claim 14, whereinthe center of gravity of the topple member is above the pivotalconnection.
 20. A furniture frame movable between a sofa configurationand a bed configuration, the furniture frame comprising: a seat portion;and a back portion operably connected with the seat portion; wherein theseat portion and the back portion are movable relative to each other toform the bed configuration of the furniture frame, in which the seatportion and the back portion are in substantially the same generallyhorizontal plane, and to form the sofa configuration of the furnitureframe, in which the seat portion and the back portion are disposed at anangle to each other; wherein the connection structure comprises meansfor toppling, the means for toppling being pivotally connected to one ofthe seat portion and the back portion at a pivotal connection, the meansfor toppling having a center of gravity disposed above the pivotalconnection, the means for toppling being constructed to move the backportion as the furniture frame moves to the sofa configuration.
 21. Amethod of moving a furniture frame, having a seat portion and a backportion, between a bed configuration and a sofa configuration, the seatportion and the back portion being in substantially the same generallyhorizontal plane in the bed configuration, the seat portion and the backportion being disposed at an angle to each other in the sofaconfiguration, the method comprising: providing a topple member, thetopple member comprising a first end and a second end, the topple memberbeing pivotally connected to the seat portion at a pivotal connectionbetween the first end and the second end; engaging the seat portion withsecond end of the topple member, separately from the pivotal connectionbetween the topple member and the seat portion; exerting a downwardforce on the seat portion; and exerting a lifting force on the backportion with the topple member to move the furniture frame to the sofaconfiguration.
 22. The method of claim 21, further comprising: liftingthe seat portion when the furniture frame is in the bed configuration,said lifting causing the second end of the topple member to engage theseat portion with a sound audible to a user of the furniture frame. 23.The method of claim 22, further comprising adjusting the sound to theliking of the user.
 24. The method of claim 22, further comprising:providing a second topple member; and causing the two topple members toengage the seat portion with two sounds audible to a user of thefurniture frame.
 25. The method of claim 21, further comprisingadjusting the center of gravity of the topple member to change themanner in which it pivots about the pivotal connection.
 26. The methodof claim 21, further comprising shipping the furniture frame in apre-assembled condition, with at least the seat portion and the backportion pivotally connected and nested into each other face-to-face. 27.A furniture frame, comprising: a first furniture panel comprising aplurality of transverse first panel slats and two longitudinal crossrails, the longitudinal cross rails contacting and supporting saidtransverse first panel slats and extending generally perpendicularthereto, the longitudinal cross rails being rigidly affixed to saidplurality of transverse first panel slats; and a second furniture panelcomprising a plurality of transverse second panel slats and onelongitudinal cross rail, said one longitudinal cross rail of the secondpanel contacting and supporting said transverse second panel slats andextending generally perpendicular thereto, said one longitudinal crossrail of the second panel being rigidly affixed to said plurality oftransverse second panel slats; wherein one of said two longitudinalcross rails of the first panel also contacts, supports and extendsgenerally perpendicular to said transverse second panel slats, saidtransverse second panel slats being constructed and arranged to rotatewith respect to said one longitudinal cross rail of the first panel asthe first panel and second panel rotate with respect to each other froma configuration in which the first panel and second panel are generallycoplanar, to a configuration in which the first panel and second panelare generally noncoplanar.
 28. The furniture frame of claim 27, whereinthe first panel and the second panel are constructed to be pivotallyconnected and nested together face-to-face in a pre-assembled conditionto reduce shipping volume.